Pressure controller and pressure control method of resistance welder

Abstract: Without increasing the dimension of the resistance welder, dressing by the respective electrode tips is made by the optimum pressurizing force. As a separate body form the resistance welder, a dressing pressure controller is provided, which controls the pressing force of the tip dresser of electrode tips of the cutter, by controlling the pressurizing mechanism and by changing the pressure of the pressurized fluid during dressing by the electrode tips of the resistance welder. Further, the piping of the pressurized fluid on the resistance welder side and the piping on the dressing pressure controller side are communicated through joints or the like, thereby enabling to open and close the flow of the pressurized fluid between the two pipings. Then, the pressurizing force during tip dressing by multiple resistance welders having a pair of electrode tips and their pressurizing mechanisms, is controlled by the single unit of the dressing pressure controller.

Description: Background of the Invention 1. Field of the Invention The present invention relates to a pressure controller for and a method of pressure control of a resistance welder having a pressurizing mechanism for pressurizing a pair of electrode tips by means of a pressurized fluid. 2. Brief Description of the Prior Art A method and equipment according to the preamble of claim 9 and claim 1, respectively, is known from EP-A-143 156. Further, a method and equipment to dress the electrode tip of a resistance welder by changing the pressing force of the electrode tip on the cutter of the tip dresser was proposed by the applicant of the present invention (see EP-A-581308). In this method and equipment, the following operations were performed: At the time of setting the electrode tip to the dresser, a comparatively weak force was used to press the electrode tip; then the electrode tip is pressed with a strong force; at the time of finish-cutting, a weak force, namely, a force which was weaker than that used to cut the flank side, was used to press the electrode tip; and while fluctuating the tip, burrs were removed at the time of cutting. While trim-cutting by changing the pressing force of the electrode tip exerted on the cutter, it was possible to lower the impact force of the electrode tip to the cutter at the time of setting, and by making the load on the cutter, etc. smaller, and at the same time, the dressing finish of the electrode tip was improved. In the past, however, the dressing pressure controller mentioned above was installed in the respective resistance welder; hence not only was the resistance welder made larger, thus occupying a larger floor area, but also there was a problem of making the unit price of the welding machine higher. In addition, when multiple resistance welder units, each supplied with an electrode tip, were connected to a single driving controller, there were problems that in order to dress the electrode tip of a single resistance welder unit, operations of other resistance welders had to be stopped and that availability of resistance welder units dropped. Further, in case of tip dresser --in which, for instance, as for the handy-type tip dresser equipped with a small-sized motor, the dresser was manually transported to the position of the electrode tip; upper and lower electrode tips were urged to the rotating blade; by rotating the rotary blade, the surface of both the electrode tips were simultaneously ground-- if at the initial step of grinding, excessive pressure-contact force was applied to the electrode tip, troubles such as excessive bite occurred, resulting in damage to the rotating blade, or application of too much torque caused heating of the driving motor. Further, after cutting, the rotating blade was stopped, without releasing the pressure-contact force of the electrode tip, there was a problem that cutting burrs occurred on the surface of the electrode tip, on which finishing had been completed. The present invention is to provide, taking the above-mentioned problems into consideration, the pressurizing controller and pressure control method, which will not make the welder too large and too expensive. It also aimed at, even when multiple resistance welder units are connected to single driving controller, making possible dressing of an electrode tip, only for the desired resistance welder unit without stopping the working state of other resistance welder units. Further, another object of the present invention is to provide a heating controller and heating control method of the resistance welder that can prevent various problems such as damage on the surface of the rotating blade and electrode tip, by causing the performance of a series of cutting operations to the electrode tips in relation to fitting operations of the tip dresser. The present invention achieves the object by the device and method according to claim 1 and 9, respectively. Thereby is effected the following : At the time of dressing the electrode tip, the supply of the pressurized fluid to the pressurizing mechanism of the resistance welder is changed over from the route at the time of ordinary welding to the route from the exclusive-use dressing pressure controller; by this dressing pressure controller, the pressing force to the same dressing pressure controller, the pressurizing force is controlled; by the same dressing pressure controller, the pressurizing force is controlled at the time of dressing the electrode tips of multiple resistance welder units. The present invention achieves the above-mentioned object by the following: separate from the resistance welder, at the time of dressing the electrode tip, the pressure of the pressurized fluid is changed to control the pressurizing mechanism; a dressing pressure controller is provided, which controls the pressing force exerted on the cutter of the tip dresser of the electrode tip, and the composition enables this single dressing pressure controller to control the pressing force of the tip dresser of the electrode tip at the time of dressing multiple resistance welder units. Further, the dressing pressure controller of the present invention can be provided with a proportional valve, which converts the pressurized fluid to a desired setting pressure, and a pressurizing solenoid valve, that controls the pressurizing mechanism of the electrode tip by changing the flow of the pressurized fluid at the dressing pressure controller. Thereby, the controller has the proportional valve on the in-flow side of the pressurized fluid and the pressurizing solenoid valve on the outflow side of the pressurized fluid. Further, it can be provided an information-receiving means to receive signals from the tip dressing pressure controller and has a composition of the pressurizing mechanism of the electrode tip, by the signal sent from this tip dresser, when the tip dresser is at the predetermined fitted position. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a block diagram showing one embodiment of the present invention; FIG. 2 is an explanatory drawing showing the relationship between the pressurizing force of the electrode tip of FIG. 1 and the elapsed time; FIG. 3 is a block diagram showing another embodiment of the present invention; FIG. 4 is a cross section showing an example of the handy-type tip dresser; FIG. 5 is a block diagram showing the composition of the control circuit of FIG. 3; FIG. 6 is a flowchart showing the cutting process of the electrode tip; and FIG. 7 is a timing chart of the cutting process of the electrode tip. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 is a block diagram showing a preferred embodiment of the present invention and shows the outlines of an air circuit and control circuit. Further, in this embodiment, explanation is given by assuming that two resistance welder units are controlled by a single drive controller. Two welder units 1 and 1' have electrode tips 2b and 2b' at their ends and are provided with fixed arms 4b and 4b', which are securely fixed to these welder units 1 and 1', oscillating arms 4a and 4a', which have electrode tips 2a and 2a' at their ends and are installed oscillation-free at these welder units 1 and 1', and pressurizing cylinder mechanisms 36 and 36', that actuate the oscillating arms 4a and 4a'. It is arranged so that the oscillating arms 4a and 4a' oscillate by actuation of the pressurizing cylinder mechanisms 36 and 36', and the oscillating arms 4a and 4a', oscillate and clamp the the work W to be welded by welding tips 2a and 2b or 2a' and 2b', thereby performing welding. Further 5 in FIG. 1 is a pressurized fluid supplier such as a compressor, which supplies pressurized liquid or air supplied from piping 10, as the pressurized fluid, that is produced from this pressurized fluid supplier to pressurizing solenoid valve 9 by way of filter 6, regulator 7, and lubricator 8. This pressurizing solenoid valve 9 activates the pressurizing cylinder mechanisms 36, 36' of the two welder units 1 and 1' by changing over the air circuit and by the command from controller 18. Numeral 19 is a conductor wire, which electrically connects the controller 18 and pressurizing solenoid valve 9 and is connected to the solenoid of pressurizing solenoid valve 9. Further, the controller 18 incorporates the welding current control circuit to supply the welding current to the electrode tips 2a, 2b; 2a', 2b' and is connected to the two welder units 1 and 1' through feeder lines 20 and 20'. In this way, by the controller 18 and pressurizing solenoid valve 9, a single drive controller 21 is composed, which controls the operations of the two welder units 1 and 1' In addition, this drive controller 21 and the two welder units 1 and 1' compose two resistance welder devices. Further, 22 is the start switch of the welder units 1 and 1' provided on the controller 18, and by turning On this start switch, welding becomes possible by the two resistance welder units. At the air outlet of the pressurizing solenoid valve 9, a pair of air pipings 13 and 13 are connected. Of these air pipings 13 and 13, one is for supplying air, which will be used to oscillate the oscillating arms 4a and 4a' to clamp the work W by a pair of electrode tips 2a, 2b; 2a', 2b', while the other is used for supplying air, which is used for reverse-operating the pressurizing cylinder mechanisms 36, 36' for releasing the clamping of the work by the electrode tips 2a, 2b; 2a', 2b', At the ends of air pipings 13, 13, switching valves 11 and 11 are provided in order to regulate air passage. These switching valves 11, 11 will, when electrode tips 2a and 2b are to be dressed by tip dresser 34, be manually or automatically closed so that air will be regulated to prevent air from flowing to pressurizing cylinder mechanism 36 from pressurizing solenoid valve 9. Switching valves 11, 11 and pressurizing cylinder mechanism 36 are connected by air piping 13a, 13a, and on the way of these air piping 13a, 13a, female couplers 15a and 16a are provided as joints. In addition, air pipings 13, 13, are branched on the way, and air pipings 14, 14 are provided which are branching pipings for supplying air to the other welder 1'. At the ends of these air pipings 14, 14, switching valves 12, 12, similar to those for air pipings 13, 13, are provided. These switching valves 12, 12 and the other welder 1' are connected by air pipings 14a, 14a, and at 14a, 14a, also, female couplers 15a' and 16a', are provided in the same way as in air piping 13a, 13a. Above-mentioned couplers 15a and 16a; 15a' and 16a' are detachably installed to male couplers 15b and 16b, of separate air pipings 30 and 31, which are connected to dressing pressure controller 3, and these female couplers 15a and 16a, 15a' and 16a' and male couplers 15b and 16b compose the secondary connection means, which permits to supply air of the predetermined pressure from the dressing pressure controller 3 to pressurized cylinder mechanism 36 (36'). Now, in female couplers 15a and 16a, 15a' and 16a', an air close-down mechanism respectively incorporated, and when no male couplers 15b and 16b are connected, air will not leak out of air pipings 13a, 13a and 14a, 14a. Next, the dressing pressure controller 3 will be explained, which is provided separately from the resistance welder, which is, at the time of tip dressing, connected to this resistance welder to press the electrode tips 2a and 2b (2a' and 2b') to the cutter of the tip dresser 34 at a predetermined pressure, and also which changes, as time passes, the pressure of air supplied to pressurizing cylinder mechanism 36 (36'), thereby changing the pressing force of electrode tips 2a and 2b (2a' and 2b') to the cutter. This dressing pressure controller 3 is composed of proportional valve 25, which reduces the pressure of air supplied from pressurized fluid supplier 5 and converts the supplied air into air having the predetermined pressure of pressurizing solenoid valve 26 which supplies the air that has been converted to the predetermined pressure by this proportional valve 25, is supplied to pressurized cylinder mechanism 36 (36'), which changes over the working direction of pressurizing mechanism 36 (36') by changing over the air circuit, and of controller 24, which electrically controls the operation of proportional valve 25 and pressurizing solenoid valve 26. Between the lubricator 8 lying on the way to air piping 10 and pressurizing solenoid valve 9, female coupler 17a is provided, and air piping 27, which has a male coupler 17b and is freely detachable at this female coupler 17a, is connected at the air inlet of the proportional valve 25. At the female coupler 17a, an air closedown mechanism is incorporated, in the way as the female coupler 17a is not connected, air will not leak out. On the other hand, at the air outlet of the pressurizing solenoid valve 26, air pipings 30 and 31 are provided, as mentioned above. The reason why the proportional valve is located on the air inlet side and the pressurizing solenoid valve is provided is to make the dressing pressure controller smaller. Namely, the air for the time of welding, which is supplied from pressurized fluid supplier 5, has high pressure, and in order to cope with such high-pressurized air, the pressurized solenoid valve will become large in size. However, since proportional valve 25 is provided on the air input side, and the pressure of the air to be supplied is reduced to the pressure necessary for tip dressing, and since the air which has become low in pressure is supplied to pressurizing solenoid valve 26, it is possible to make pressurizing solenoid valve 26 smaller in size. Therefore, it has become convenient to carry dressing pressure controller 3, when the electrode tip of another resistance welder unit is to be dressed. Further, the reason why two air pipings 30 and 31 are provided for pressurizing solenoid valve 26 is due to the same reason as in the case of air pipings 13, 13 connected to pressurizing solenoid valve 9. In addition, if the connection-use air pipings 27, 30 and 31 are, as shown in the Figure, made detachable from dressing pressure controller 3, using couplers 17c, 17d, 28a, 28b, 29a and 29b respectively, it will become convenient for moving and storing the dressing pressure controller 3. The controller 24 is electrically connected respectively to proportional valve 25 and pressurizing solenoid valve 26, and when the set pressurizing electric current, which corresponds to the pressurizing force to be applied to electrode tips 2a and 2b (2a' and 2b') at the time of tip dressing, is generated from controller 24, the introduced air is converted to the air at the predetermined pressure by proportional valve 25, and at the same time, a command signal for actuating the solenoid is applied to pressurizing solenoid valve 26 and air at the predetermined pressure is supplied to pressurizing cylinder mechanism 36. Further, 32 is a hand-side switch for starting dressing controller 3, which is electrically connected to controller 24 by connection wiring 32a. The operator can carry out work, while constantly monitoring tip dresser 34, by operating this hand-side switch 32. In the present preferred embodiment, by separately composing dressing pressure controller 3 from the resistance welder, this hand-side switch 32 together with dressing pressure controller 3 are also made separable from the resistance welder; hence there is no need of protecting connection wiring 32a and hand-side switch 32 from spattering during welding operation, and this setup also has a feature that long connection wiring 32a will not be in the way of operation. FIG. 2 shows a chart showing the relation between pressurizing force, which is applied to electrode tips 2a and 2b (2a' and 2b') and the elapsed time. In the pressure setting Table shown in this Figure, the abscissa represents time T (sec), while the ordinate represents pressurizing force (kgf). First, at electrode tip setting time T1, setting pressure is made lower to Level 3. Then (a) "preliminary pressurizing" is carried out, and from the time when electrode tips 2a, 2b and side blade of the cutter come into contact, the set pressure is raised to Level 2; (b) "rough working pressure" is performed. Next, until the electrode tip side cutting time T2 ends, Level 2 is maintained, and before entering the end-side cutting of electrode tips 2a and 2b is commenced, air pressure is decomposed to level 4; (c) "finish-working" is performed, and this Level 4 is maintained, until the electrode-tip end-surface cutting time T3 ends. After the cutting of electrode tips 2a and 2b ends, the set pressure is raised to level 1; and (d) "pressurizing at the time of welding" is set. Next, explanation is given to the operation of the present preferred embodiment, composed above. Air supplied from pressure fluid supplier 5, such as the compressor, flows into pressurizing solenoid valve 9 by way of air piping 10. In the pressurizing solenoid valve, the air circuit is changed over according to the control signal from controller 18, air is supplied for welding operation to pressurizing cylinders 36 and 36' of welder units 1 and 1' by way of air pipings 13 and 13a, and air pipings 14 and 14a. At the time of welding, oscillating arms 4a and 4a' oscillate, work W is clamped by welding tips 2a, 2b, 2a' and 2b', and welding operation is carried out responsive to the command signal from controller 18. After welding operation is ended, pressurizing solenoid valve 9 changes over the air circuit by reverse-working pressurizing cylinders 36 and 36', and the clamping of work W by welding tips 2a, 2b, 2a' and 2b', is released. When electrode tips 2a and 2b of one resistance welder unit are to be dressed, turn OFF starting switch 22 to put welder units 1 and 1' into non-working states, and close switching valves 11, 11 to stop the air flow from pressurizing solenoid valve 9 to pressurized cylinder 36. Next, dressing pressure controller 3 is connected to resistance welder. At this time, male-type coupler 17b of air piping 27, which has been connected to proportional valve 25 is engaged and connected to female-type coupler 17a of air piping 10, and at the same time, male-type coupler 15b and 16b of air piping 30 and 31, which have been connected to pressurizing solenoid valve 26, are engaged and connected to female-type couplers 15a and 16a. Then the cutter of tip dresser 34 between electrode tips 2a and 2b should be arranged, and hand-side switch 32 to start the operation of dressing pressure controller 3 should be turned on. Proportional valve 25 decomposes air, which has been supplied from air piping 10 in accordance to set pressurized electric current, and sends air, which has risen to the predetermined pressure, to pressurized solenoid valve 26. Pressurized solenoid valve 26 supplies air of the predetermined pressure, by the command signals from controller 24, to pressurizing cylinder mechanism 36 by way of air piping 13a. By this air supply, oscillating arm 4a oscillates and presses electrode tips 2a and 2b against the cutter of tip dresser 34. After that, proportional valve 25 converts air pressure according to changes in the pressurizing electric current, which is generated from controller 24, proportional valve 25 converts air pressure, thereby changing pressing force of electrode tips 2a and 2b to the cutter according to the setting based on the chart shown in FIG. 2. In this case, switching valves 11, 11 are closed and therefore, air from pressurizing solenoid valve 26 will not flow to the sides of pressurizing solenoid 9 and other welder unit 1'. If dressing operation of the electrode tips 2a and 2b is completed, all the operations to be done are; to turn OFF the hand-side switch 32, to remove connecting-use air pipings 27, 30 and 31 from air pipings 10, 13a and 13a, and to open switching valves 11, 11. When the starting switch 22 is turned ON, welders 1 and 1' become the condition of being capable of starting welding operation. At the time of dressing electrodes tips 2a' and 2b' of the other resistance welder unit, close switching valves 12, 12, so that air will not flow from pressurizing solenoid valve 9 to pressurizing cylinder 36'. Then engage and connect female couplers 15b and 16b to female couplers 15a' and 16a'. Thereafter, repeat the same operations mentioned above. By installing switching valves 11 and 12 in front of each welder 1 and 1', it has become possible to carry out tip dressing operation by one welder unit 1 (1'), and it has become also possible to carry out tip dressing operation by one welder unit 1 (1') and simultaneously to carry out ordinary welding operation by the other welder 1' (1), thereby making it also possible to improve the availability of resistance welders. In the above-mentioned preferred embodiment, it has been explained that the operations of two units of resistance welders may be controlled by a signal drive controller 21, in the case of three or more resistance welder units, air piping 14, 14 or air pipings 13, 13 may be branched according to the number of resistance welder units. According to the present embodiment, even in the case of increasing the number of resistance welder units, and it has been made so that dressing pressure controller 3 can be connected to the resistance welder, only at the time of tip dressing, so that tip dressing can be performed. As a result, it has become unnecessary to provide dressing pressure controller 3 to each of resistance welder units, thereby making the resistance welder smaller and cheaper and has made it possible to use a single dressing pressure controller 3 universally to other resistance welders. In addition, by installing proportional valve 25 at the inlet side of pressurized fluid of the dressing pressure controller 3, and by providing pressurizing solenoid valve 26 on the output side, dressing pressure controller 3 can be made smaller in size and easier to transport. It is further possible to connect plural resistance welder units to a single driving controller 21, and to provide switching valves 11, 12 and connecting means by joints to respective branching pipes, which distribute air, so that tip dressing operation and welding operation can be performed in parallel, thereby preventing the drop in availability of resistance welders. In the above-mentioned preferred embodiment, as the first connection means for supplying pressurized fluid (air in the present embodiment) to dressing pressure controller 3 at the time of dressing of the electrode tip, and as the second connection means for supplying the pressurized fluid from the dressing pressure controller 3 to pressurizing cylinder mechanisms 36 and 36', a joint (female-type coupler), which is provided at the piping of the pressurized fluid, and a joint (male-type coupler), which has been provided at the dressing pressure controller 3, which is engaged with the joint in a freely detachable manner, but in place of these joints, it is also possible to compose a connecting means by using a branching piping, that communicates the piping of the pressurized fluid and dressing pressure controller 3, and a switching valve engaged with this branching piping. FIG. 3 is a composition drawing showing another preferred embodiment of the present invention. FIG. 4 is a side view showing an example of the handy-type tip dresser to be used in grinding the electrode tip, and FIG. 5 is a block diagram showing the composition of the control circuit provided on the resistance welder. in FIGS.3 to 5, 101 is the welder proper, and on this welder 101, fixed securely on work table 102 of the welder by way of energizing plate 103, and upward from this, movable electrode tip 106, which is vertically operated by elevating pressurized cylinder mechanism 105, is provided face to face by way of energizing plate 107. The elevating pressurizing cylinder mechanism 105 operates by pressurized air from high-pressure air supply source (pressurized fluid supplier) 110 that is supplied by way of pressure conversion valve 108, and solenoid valve 109 of the self-recovering type is composed to be able to change pressurizing force to handy-type tip dresser 113 to be mentioned later and further, these motions are composed to be controlled by signals from the light receiver (transmitting means) 117. On the other hand, the handy-type tip dresser 113 simultaneously grinds these electrode tip 104 and movable electrode tip 106, and this tip dresser 113 is, as shown in FIG. 4, composed to grind electrode tips 104 and 106, that have been inserted through tip insertion ports 114 and 115, which have been provided at the upper and lower surfaces, to rotate blade 116, which is driven by a driving motor (not shown in the Figure). Further, on this tip dresser 113, the light emitter 117 is provided, which lies face to with the light receiver 111, that was provided on the welder 101, which was installed in matching with fixed electrode tip 104. At the grip 118 of the light emitter 117, a two-stage switch 119 is provided, which operates the driving motor inside by the first stage and causes light emitter 117 to emit light at the second stage. On the other hand, control circuit 120, shown in FIG. 5 controls various operations of pressure conversion valve 108 and electromagnetic change-over valve 109 and ON-OFF of the welding power source. Circuit insulation means 121 is so constructed that it receives output signals from light receiver 111, works on main circuit switch 132 of circuits of thyristors, etc., from welding power source 131 to electrode tips 104 and 106, thereby cutting off the circuit. Operation signal producing means 122 remembers the sequences set by the external setting means such as the keyboards or floppy disk, and in the present preferred embodiment, the operation signals from light receiver 111, it will generate three times of operation signals to valve control means 123. On the other hand, it is so composed that it will generate the fourth signal to valve control means 123 and change-over means 125. Further, valve control means 123 will, if it receives from operation signal producing 122 the first-time operation signal, cause movable electrode tip 146 to apply pressurizing force of, for instance, 70 Kgf. If operation signals of two to four times are received, it has been set beforehand by the setting means 128 to cause movable electrode tip 106 to operate pressure conversion valve 108 in order to apply pressurizing force of 130Kgf, 30Kgf and 230Kgf, respectively. Valve driving means 126 is so composed that when it receives a detection signal from light emitter 111, it receives a pressurizing signal to electrode change-over means 119 from change-over means 125 by way of operation signal producing means 122 and applies to electrode change-over means 119 a signal that will lower movable electrode tip 106. On the other hand, it is also so composed that when it receives a pressurization releasing signal from change-over means 125, it produces to solenoid valve 109 a signal that will elevate movable electrode tip 106. Next, operations of the equipment, which has been composed as mentioned above, will be explained on the basis of the flow chart in FIG. 6 and the timing chart in FIG.7. First, handy-type tip dresser is fitted to fixed electrode tip 104 (Step S1) Under this condition, second-stage switch 11, provided at grip 118, is given one-stage pushing operation (Step S2), rotary blade 116 is rotated by starting the driving motor (not shown in the Figure) (Step S3), and second-stage switch 119 is further pushed (Step S4) and light emitter 117 is caused to emit light (Step S5). By these operations, light receiver 111 at the side of welder 101 receives light from light emitter 117 and detects that tip dresser 12 has been fitted to the predetermined position (Step S6) and applies the detection signal to circuit insulting means 121, and insulate the circuit of welding power source 131 that leads to electrode tips 104, 106 (Step S7). On the other hand, valve driving means 126, which has received detection signals from the light receiver, operates electromagnetic switching valve 109 in order to introduce pressurized air into the upper chamber of elevating-use pressurizing cylinder 105. At the same time, operation signal producing means 122 applies the first-time signal to valve 108, so that pressurizing force will become 70 Kgf and movable electrode tip will come into contact with rotary blade 116 with weak force (Step S8). As a result, the elevating-use pressurizing cylinder mechanism 105 lowers movable electrode tip 106 on to rotary blade 116 with weak force (Step S9), and without causing strong torque fluctuations to rotating rotary blade 116, without giving excessive gouging to electrode tips 104 and 106 and without giving damage to rotary blade 116, these electrode tips are made to slide into above and below of rotary blade 116. When a predetermined time expires, then, by the second-time operation signal from operation signal producing means 122, pressure conversion valve 108 is operated by way of valve controlling means 123, the pressure of pressurized air, which is to be supplied to the elevating-use pressurizing cylinder mechanism, is increased to 130 kgf by tip pressurizing force conversion calculation, and with this pressurizing force, the ends and sides of both electrode tips 104 and 106 are roughly dressed (step S10). When this rough dressing is ended, pressure of pressurized air is reduced to 30 Kgf by tip pressurized force conversion calculation by the third-time signal from operation signal producing means 122, and surfaces of both electrode tips 104 and 106 are finish-worked (Step S11). The after switching off light emitter 17 by way of two-stage switch 119, (Step S12), valve control means 123 will, when it receives the fourth-time signal from operation signal producing means 122, control pressure control valve 108, and increase the pressure of pressurized air to 230 Kgf by the pressurized temperature conversion calculation, and simultaneously change-over means 125 applies signals to valve driving means 126 to change over solenoid valve 109 to the "releasing" side (Step S13); the pressurized air, which has been raised in pressure to 230 Kgf by tip pressurizing temperature conversion calculation, is directed to the lower chamber of elevating-use pressurizing cylinder mechanism 105, and movable electrode tip 106 is rapidly separated from rotary blade 116, thereby increasing the pressure of pressurized air 9 Step S14). When a series of operations are ended in this way, finally two-stage switch 119 is operated to turn off the first-stage switch (Step S15), and the driving motor is stopped )Step S16), thereby completing a series of operations. In the above-mentioned preferred embodiment, light emitter 117 and light receiver 111 were provided on tip dresser 113 and welder 101, but the above can be replaced by providing a transmitter and receiver using general electromagnetic waves. In this way, tip dresser 113 is provided with a transmission means that will produce signals following the rotating operation of rotary blade 116. On the other hand, the pressurizing mechanism, which has been provided on the welder side, has been made to operate by the detection output from the receiving means, that will produce by receiving signals from the transmitting means; hence it has enabled to supplies abnormal contact between electrode tips 104 and 106 and rotary blade 116 due to miss-operation or miss-fitting of tip dresser 113, thereby preventing accidents such as excessive gouging into electrode tips 104 and 106, damage to rotary blade 116 or heating of the driving motor. Further, pressure of pressurized fluid to be supplied to the elevating-use pressurizing mechanism has been made to change according to "initial contact", "rough grinding" and "finishing". As a result, it has become possible to make the initial contact with rotary blade 116 moderate and to carry out grinding by electrode tips 104 and 106 more effectively and more precisely.

Claims: A pressure controller for a resistance welder (1, 1') having a pressurizing mechanism (36, 36') for pressurizing a pair of electrode tips (2a, 2b, 2a', 2b') by means of pressurized fluid, said pressure controller comprising: a pressurized fluid supplier (5) for supplying said pressurized fluid; a pressurizing electromagnetic valve (9) for controlling said pressurizing mechanism (36, 36') by changing over the flow of said pressurizing fluid from said pressurized fluid supplier (5) to said pressurizing mechanism (36, 36') during welding; a welding controller (18) for controlling said pressurizing electromagnetic valve (9); a dressing pressure controller (3) for controlling the pressing force of the electrode tips to be dressed exerted on a cutter of a tip dresser (34) during dressing said electrode tips (2a, 2b, 2a', 2b') by changing the pressure of said pressurized fluid supplied to said pressurizing mechanism (36, 36'); first connecting means (17a, 17b, 17c, 17d, 27) for supplying, during dressing, pressurized fluid from the pressurized fluid supplier (5) to said dressing pressure controller (3); second connecting means (28a, 28b, 29a, 29b, 30, 31, 15a, 16a, 15a', 16a', 15b, 16b) for supplying, during dressing, pressurized fluid from the dressing pressure controller (3) to said pressurizing mechanism (36, 36') associated to the electrode tips to be dressed; and a switching valve means (11, 12) for controlling the flow of pressurized fluid from said pressurizing electromagnetic valve (9) to said pressurizing mechanism (36, 36'); characterized in that said switching valve means (11, 12) comprises a plurality of switching valves (11, 12) for controlling the flow of pressurized fluid to a plurality of resistance welder units (1, 1') each having a pressurizing mechanism (36, 36') for pressurizing a pair of electrode tips (2a, 2b, 2a', 2b'), in that said dressing pressure controller (3) is provided separately from said resistance welder (1, 1'), and in that said first connecting means (17a, 17b, 17c, 17d, 27) and said second connecting means (28a, 28b, 29a, 29b, 30, 31, 15a, 16a, 15a', 16a', 15b, 16b) are detachable. A pressure controller according to claim 1, wherein said first connecting means (17a, 17b, 17c, 17d, 27) include a joint (17a) provided at a piping (10) of the pressurized fluid between said pressurized fluid supplier (5) and said pressurizing electromagnetic valve (9), and another joint (17d) provided at the side of said dressing pressure controller (3) detachably engaged with said joint (17a). A pressure controller according to claim 1, wherein said first connecting means (17a, 17b, 17c, 17d, 27) include a branching pipe in communication with a piping (10) of said pressurized fluid between said pressurized fluid supplier (5) and said pressurizing electromagnetic valve (9), and a switching valve interposed in said branching pipe. A pressure controller according to claim 1, 2 or 3, wherein said second connecting means (28a, 28b, 29a, 29b, 30, 31, 15a, 16a, 15a', 16a', 15b, 16b) include a joint (15a, 16a, 15a', 16a'), which is provided on a piping (13a, 14a) of the pressurized fluid between said switching valves (11, 12), that control the flow of the pressurized fluid from the pressurizing electromagnetic valve (9) to the pressurizing mechanism (36, 36'), and said pressurizing mechanism (36, 36'), and wherein another joint (28b, 29b) is provided at the side of said dressing pressure controller (3), this joint (28b, 29b) being detachably engaged with said joint (15a, 16a, 15a', 16a'). A pressure controller according to claim 1, 2 or 3, wherein said second connecting means (28a, 28b, 29a, 29b, 30, 31, 15a, 16a, 15a', 16a', 15b, 16b) include a branching pipe (30, 31) in communication with a piping (13a, 14a) of said pressurized fluid between the switching valves (11, 12) controlling the flow of the pressurized fluid from the pressurizing electromagnetic valve (9) to the pressurizing mechanism (36, 36'), and said pressurizing mechanism (36, 36'), and a switching valve interposed in said branching pipe. A pressure controller according to claim 1 to 5, wherein said dressing pressure controller (3) includes a proportional valve (25) to convert the pressure of said pressurized fluid to a predetermined pressure responsive to a signal, which is representative of the set pressure during dressing, and a pressurizing solenoid valve (26) for controlling said pressurizing mechanism (36, 36') by switching the flow of pressurized fluid, said proportional valve (25) being provided at the fluid inlet side of the dressing pressure controller (3) and said pressurizing solenoid valve (26) being provided at the fluid outlet side of the dressing pressure controller (3). A pressure controller according to claim 1 to 6, further comprising receiving means (111) to receive a signal from transmitting means (117), when the tip dresser (34) is at a predetermined fitting position, wherein said dressing pressure controller (3) controls the pressurizing mechanism (36, 36') by receiving the signal detection output from said receiving means (111). A pressure controller according to claim 1 to 7, further comprising a pressure change-over means (125) for changing over the pressurizing force, selectively in time series, between forces, these forces including the force required to cause initial-period contact of the electrode tips (2a, 2b, 2a', 2b') with the cutter of the tip dresser (34), the force required to carry out rough grinding and the force required for finishing. A method of pressure control for a resistance welder (1, 1') having a pressurizing mechanism (36, 36') for pressurizing a pair of electrode tips (2a, 2b, 2a', 2b') by means of a pressurized fluid, wherein the pressing force applied on the electrode tips (2a, 2b, 2a', 2b') is controlled during welding by supplying pressurized fluid to the pressurizing mechanism (36, 36') through a passage used for pressurizing the pressurizing mechanism (36, 36') during welding, and the pressing force applied on the electrode tips to be dressed is controlled during dressing by a dressing pressure controller (3), said method comprising: changing over the supply of the pressurizing fluid for the pressurizing mechanism (36, 36') from the passage used for pressurizing the pressurizing mechanism (36, 36') during welding to another passage, used exclusively for pressurizing the pressurizing mechanism (36, 36') during dressing, and connected to the dressing pressure controller (3); characterized in that the dressing pressure controller (3) can be detachably connected to the passage used for pressurizing during welding.

Inventors: GOTO TADASHI, HOSHINO SHINJI, MACHIMURA SATORU, MOCHIZUKI TOSHITAKA, NAKAJIMA TOSHIHARU, OHTANI HIROSHI, GOTO, TADASHI, HOSHINO, SHINJI, MACHIMURA, SATORU, MOCHIZUKI, TOSHITAKA, NAKAJIMA, TOSHIHARU, OHTANI, HIROSHI
Applicants: HONDA MOTOR CO LTD, HONDA GIKEN KOGYO KABUSHIKI KAISHA
Application year: 1994
Main classification: B23K11
IPC codes: B23K11